Thin-profile battery electrode connection members, button-type battery electrode connection members, thin profile battery constructions and button-type battery constructions

ABSTRACT

Thin-profile battery electrode connection members, button-type battery electrode connection members, thin-profile battery constructions, button-type battery constructions, and methods of establishing electrical connections with and between both thin-profile batteries and button-type batteries are described. In one implementation, an electrode connection member comprises an inner conductive surface, and outer peripheral conductive surface, and an intermediate conductive surface joined with and extending between the inner and outer surfaces. The connection member defines an internal volume which is sized to receive at least one thin-profile battery. In one aspect, the intermediate conductive surface tapers between the inner and outer surfaces. The taper enables more than one thin-profile battery to be mounted within the internal volume without the need for edge insulation material over one of the batteries to prevent grounding. The electrode connection member can be mounted on a substrate for providing a generally self-contained, space-conserving power source which can include more than one battery connected in a series electrical connection.

RELATED PATENT DATA

This patent resulted from a continuation application of U.S. patentapplication Ser. No. 08/954,224, filed Oct. 20, 1997, entitled“Thin-Profile Battery Electrode Connection Members, Button-Type BatteryElectrode Connection Members, Thin-Profile Battery Constructions,Button-Type Battery Constructions, Methods Of Forming Thin-ProfileBattery Electrode Connection Members, Button-Type Battery ElectrodeConnection Members, Thin-Profile Battery Constructions, And Button-TypeBattery Constructions, And Methods Of Establishing ElectricalConnections”, naming Rickie C. Lake as inventor, and which is now U.S.Pat. No. 5,998,061, the disclosure of which is incorporated byreference.

TECHNICAL FIELD

This invention relates to thin-profile battery electrode connectionmembers, button-type battery electrode connection members, thin-profilebattery constructions, button-type battery constructions, and methods ofestablishing electrical connections with and between both thin-profilebatteries and button-type batteries.

BACKGROUND OF THE INVENTION

Thin-profile batteries are characterized by having thickness dimensionswhich are less than a maximum linear dimension of its anode or cathode.One type of thin-profile battery is a button-type battery. Suchbatteries, because of their compact size, permit electronic devices tobe built which themselves are very small or compact. When a highervoltage is needed in such devices, the batteries can be stacked orcascaded with one another to achieve a series electrical connection.When the electrical devices with which such batteries are used are smallin dimension, it is desirable to configure one or more of the batteriesin such a way as to conserve or minimize the space requirementsnecessary to achieve a desirable electrical connection between thebatteries and other components of the device.

This invention arose out of concerns associated with improving thestructures and methods through which thin-profile or button-typebatteries are interconnected with one another and with electricaldevices.

SUMMARY OF THE INVENTION

Thin-profile battery electrode connection members, button-type batteryelectrode connection members, thin-profile battery constructions,button-type battery constructions, and methods of establishingelectrical connections with and between both thin-profile batteries andbutton-type batteries are described. In one implementation, an electrodeconnection member comprises an inner conductive surface, and outerperipheral conductive surface, and an intermediate conductive surfacejoined with and extending between the inner and outer surfaces. Theconnection member defines an internal volume which is sized to receiveat least one thin-profile battery. In one aspect, the intermediateconductive surface tapers between the inner and outer surfaces. Thetaper enables more than one thin-profile battery to be mounted withinthe internal volume without the need for edge insulation material overone of the batteries to prevent grounding. The electrode connectionmember can be mounted on a substrate for providing a generallyself-contained, space-conserving power source which can include morethan one battery connected in a series electrical connection.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below withreference to the following accompanying drawings.

FIG. 1 is a side sectional view of an electrode connection member formedin accordance with one aspect of the invention.

FIG. 2 is a top plan view of the FIG. 1 electrode connection member.

FIG. 3 is a side sectional view of an electrode connection member formedin accordance with another aspect of the invention.

FIG. 4 is a side sectional view of the FIG. 1 electrode connectionmember within which a thin-profile battery is received.

FIG. 5 is a side sectional view of an electrode connection member whichis formed in accordance with another aspect of the invention and withinwhich two thin-profile batteries are received.

FIG. 6 is a view of the FIG. 4 electrode connection member mounted on asubstrate.

FIG. 7 is a view of the FIG. 5 electrode connection member mounted on asubstrate.

FIG. 8 is a view of an exemplary electronic device which incorporates anelectrode connection member and battery stack in accordance with theinvention.

FIG. 9 is a view which is taken along line 9—9 in FIG. 1.

FIG. 10 is a view which is taken along line 10—10 in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of theconstitutional purposes of the U.S. Patent Laws “to promote the progressof science and useful arts” (Article 1, Section 8).

Referring to FIGS. 1, 2, 9, and 10, a connection member or container isshown generally at 20 and is configured for use with at least onethin-profile or button-type battery. Connection member 20 can compriseany suitable conductive material such as nickel foil, stainless steelsheet, metal screen mesh, and the like, and can be formed by stamping,etching, drawing, or molding any of such materials. Connection member 20includes an inner conductive electrode connection surface 22 which issized to receive and form an electrical connection with a batteryelectrode surface as will become apparent below. A battery electrodesurface is mounted over or atop surface 22 and can be fixed in placewith conductive epoxy. Accordingly, surface 22 can be considered as amounting surface. At least a portion of surface 22 is generally planarand is oriented within a mounting surface plane P₁. Connection surface22 has an outermost boundary edge 24 which is generally circular inshape.

A conductive side or intermediate surface 26 is provided and is joinedwith connection surface 22 proximate outermost boundary edge 24. Theoutermost boundary edge defines a joinder location between surfaces 22,26, with both surfaces extending generally away therefrom. In theillustrated example, surface 26 tapers to extend generally outwardlyfrom connection surface 22 and define a generally frustum-shaped sidesurface.

An outer peripheral conductive surface or rim 28 is provided and isjoined with side surface 26 proximate a joinder location 30. Outersurface or rim 28 defines an opening into an internal volume 32 which isdefined by connection surface 22 and side surface 26. Internal volume 32is sized to receive a substantial portion of at least one thin-profileor button-type battery. Side surface 26 tapers generally outwardly fromjoinder location 24 toward joinder location 30. The rim defines aterminus of side surface 26. Outer surface 28 is oriented within a planeP₂ which is generally parallel with plane P₁. Side surface 26 includesat least a portion which extends away from plane P₁ at an angle θ whichis generally oblique relative thereto. Other angles θ are of coursepossible. In the illustrated example, a substantial portion of sidesurface 26 extends away at the angle θ. Surface 26 is dimensioned toachieve substantial alignment between outer surface 28 and a batteryelectrode surface of a thin-profile or button-type battery which isreceived within connection member 20.

In one aspect, connection member 20 has a thickness dimension t adjacentinner conductive surface 22 and in a direction A which is normal toplane P₁. Outer surface or rim 28 includes first and second boundaryedges 34, 36 respectively, which have a minimum separation distance dtherebetween. First and second boundary edges 34, 36 are generallycircular in shape and concentric with one another. In the illustratedexample, minimum separation distance d is greater than the thicknessdimension t of connection member 20.

FIG. 3 shows a connection member 20 which is similar in construction tothe FIG. 1 connection member except that outer surface or rim 28 definesa minimum separation distance d which is approximately equal tothickness dimension t.

FIGS. 9 and 10 illustrate different cuts which are taken throughconnection member 20 of FIG. 1. FIG. 9 shows a first portion or cutcomprising side surface 26 which is taken through line 9—9 in FIG. 1.FIG. 10 shows a second portion or cut comprising side surface 26 whichis taken through line 10—10 in FIG. 1. The side surface portions boundrespective first and second areas inside surface 26 and within internalvolume 32 which lie in respective first and second planes. The first andsecond planes are spaced from one another and the areas definedtherewithin are different from one another. In the illustrated example,the first and second planes are generally parallel with one another andwith plane P₁. The first plane (FIG. 9) is disposed closer to connectionsurface 22 than the second plane (FIG. 10). In the illustrated example,the first area is less than the second area.

Referring to FIG. 4, an exemplary thin-profile battery comprising abutton-type battery 38 is placed or mounted on connection member 20 andreceived within internal volume 32. Battery 38 includes a pair ofterminal housing members which define a pair of outwardly-facingelectrodes 40, 42. Electrode 40 comprises the lid or anode electrode ofthe battery and electrode 42 comprises the can or cathode electrode ofthe battery. Side surface 26 is dimensioned to achieve substantialalignment of outer surface 28 and electrode surface 40. Such is observedas plane P₂ is seen to be generally coincident with surface 40.Electrode 42 is conductively received against surface 22 and accordinglyestablishes electrical communication between electrode surface 42 andconnection member 20. Accordingly, a single battery is provided andcomprises different respective surfaces with which electrical connectionis made with connection member 20, and substantial alignment is achievedwith outer surface 28. Conductive adhesion with epoxy or other suitablebonding techniques such as welding can be utilized to fixedly mountbattery 38 within connection member 20, if desired.

Referring to FIG. 5, a connection member which is formed in accordancewith an alternate embodiment of the present invention is shown generallyat 20 a. Like numerals from the above-described embodiment are utilizedwhere appropriate, with differences being indicated by the suffix “a” orwith different numerals. Accordingly, mounting surface 22 a and sidesurface 26 a define an internal volume 32 a which is sized to receivesubstantial portions of two thin-profile batteries 44, 46. For purposesof the ongoing discussion, battery 44 comprises a first battery andbattery 46 comprises a second battery. The batteries are oriented in astack, one atop the other, and can be conductively bonded together ifdesired. Battery 44 includes a pair of terminal housing memberscomprising lid and can terminals. The lid and can terminals respectivelydefine a pair of outwardly-facing battery electrode surfaces 48, 50.Battery 46 includes a pair of terminal housing members comprising lidand can terminals. The lid and can terminals respectively define a pairof outwardly facing battery electrode surfaces 52, 54. Side surface 26 ais dimensioned to achieve substantial alignment of outer surface 28 aand battery electrode surface 52. Accordingly, substantial alignment isachieved with an electrode surface of a different battery from whichdesired electrical connection is made with connection surface 22 a.

Side surface 26 a of connection member 20 a extends away from connectionsurface 22 a sufficiently to bring at least a portion of the sidesurface into abutting physical engagement with only one of the batteriesreceived within internal volume 32 a. In the illustrated example, suchabutting engagement is achieved with battery 44 only and not withbattery 46 by imparting a desired degree of taper to side surface 26 a.The illustrated side surface 26 a is generally frustum-shaped which issimilar to the one-battery embodiment of FIG. 4. By virtue of theangularity of side surface 26 a relative to surface 22 a, no electricalinsulation is necessary to protect battery 46 from undesirably groundingagainst the side surface. Such insulation can, however, be provided ifdesired.

FIGS. 6 and 7 show a substrate portion 56 having a generally planarsubstrate surface 58. The substrate can comprise a printed circuitsubstrate, i.e. printed circuit board, or a flexible circuit board andthe like. A pair of spaced electrical contacts or contact pads 60, 62are supported by substrate 56. Contact 60 comprises two different spacedportions which are each laterally spaced from contact 62. Exemplarymaterials for the contact pads include screen- or stencil-printedconductive materials such as copper or conductive printed thick film(PTF). The material from which contacts 60, 62 are formed can be eitherrecessed within substrate 56 or disposed atop the substrate. In thecontext of this document, both constructions are seen to provide agenerally planar outer surface adjacent which one or more batteries canbe mounted or received.

Outer surfaces or rims 28 (FIG. 6), 28 a (FIG. 7) are disposed againstsubstrate surface 58. Surface 58 substantially encloses the battery orbatteries received within the respective internal volumes 32, 32 a.Accordingly, containers 20, 20 a and substrate surface 58 definerespective enclosures 64, 64 a inside of which a battery or batteriesare received. Electrode surfaces 40 (FIG. 6), 52 (FIG. 7) areconductively received against contact pad 62, while outer surfaces 28,28 a are conductively received against contact pad 60. Outer surfaces28, 28 a can be conductively bonded to the contact pads by conductiveepoxy. Accordingly an electrical circuit connection is formed.

Referring to FIG. 7, batteries 44, 46 are conductively connectedtogether in a stack which defines a series electrical connection. Afirst electrical connection is defined between electrode surface 48 ofbattery 44 and electrode surface 54 of battery 46. Such electricalconnection can arise from a mere physical engagement of the batteries orthrough the application of a suitable conductive epoxy material or otherbonding agent to effectively conductively bond the two together. Asecond electrical connection is provided between electrode surface 50 ofbattery 44 and electrode surface 52 of battery 46. In the illustratedexample, the second electrical connection is provided through therespective contact pads which operably connect with circuitry which isexternal to the batteries. An exemplary arrangement is shown in FIG. 8where a single integrated circuitry chip 66 is mounted over substrate56. Connection member 20 a is received over the substrate and operablymounted thereon so that the batteries are placed into electricalcommunication with chip 66. The contact pads are defined by conductivetraces which form, together with chip 66, the second electricalconnection mentioned above. In the illustrated and preferred embodiment,chip 66 is configured for wireless radio frequency communication. Anexemplary chip is described is U.S. patent application Ser. No.08/705,043, which names James O'Toole, John R. Tuttle, Mark E. Tuttle,Tyler Lowrey, Kevin Devereaux, George Pax, Brian Higgins, Shu-Sun Yu,David Ovard and Robert Rotzoll as inventors, which was filed on Aug. 29,1996, is assigned to the assignee of this patent application, and isfully incorporated herein by reference.

In compliance with the statute, the invention has been described inlanguage more or less specific as to structural and methodical features.It is to be understood, however, that the invention is not limited tothe specific features shown and described, since the means hereindisclosed comprise preferred forms of putting the invention into effect.The invention is, therefore, claimed in any of its forms ormodifications within the proper scope of the appended claimsappropriately interpreted in accordance with the doctrine ofequivalents.

What is claimed is:
 1. A thin-profile battery electrode connectionmember comprising: a conductive battery electrode connection surface;and a conductive generally frustum-shaped side surface joined with theconnection surface and defining together therewith an internal volumesized to receive at least most all of at least one thin-profile batteryhaving a thickness which is less than a maximum linear dimension of thethin-profile battery.
 2. The thin-profile battery electrode connectionmember of claim 1, wherein the side surface tapers outwardly from theelectrode connection surface.
 3. The thin-profile battery electrodeconnection member of claim 1, wherein the electrode connection surfaceis generally circular in shape and the side surface tapers generallyoutwardly from the electrode connection surface.
 4. A thin-profilebattery electrode connection member comprising: a conductive batteryelectrode connection surface; and a conductive generally frustum-shapedside surface joined with the connection surface and defining togethertherewith an internal volume sized to receive substantial portions ofeach of at least two thin-profile batteries having a respectivethickness which is less than a maximum linear dimension of therespective thin-profile battery.
 5. The thin-profile battery electrodeconnection member of claim 4, wherein the side surface extends away fromthe electrode connection surface sufficient to bring at least a portionof the side surface into abutting engagement with only one of thethin-profile batteries.
 6. The thin-profile battery electrode connectionmember of claim 4, wherein the side surface tapers outwardly from theelectrode connection surface.
 7. The thin-profile battery electrodeconnection member of claim 4, wherein the side surface tapers outwardlyfrom the electrode connection surface and defines a desired degree oftaper, the desired degree of taper being sufficient to bring a least aportion of the side surface into abutting engagement with only one ofthe thin-profile batteries.
 8. The thin-profile battery electrodeconnection member of claim 4, wherein the internal volume is sized toreceive substantial portions of each of at least two thin-profilebatteries in a stack.
 9. A button-type battery electrode connectionmember comprising: a conductive button-type battery electrode connectionsurface; and a conductive generally frustum-shaped side joined with theconnection surface and defining together therewith an internal volumesized to receive at least most all of at least one button-type battery.10. A button-type battery electrode connection member comprising: aconductive button-type battery electrode connection surface; and aconductive generally frustum-shaped side surface joined with theconnection surface and defining together therewith an internal volumesized to receive substantial portions of each of at least twobutton-type batteries.
 11. The button-type battery electrode connectionmember of claim 10, wherein the frustum-shaped side surface comprises aportion which physically engages only one of the at least twobutton-type batteries.
 12. The button-type battery electrode connectionmember of claim 9, wherein the internal volume is sized to receivesubstantial portions of at least two button-type batteries which arestacked one atop the other and wherein the frustum-shaped side surfaceis configured to physically engage only one of the at least twobutton-type batteries.
 13. A thin-profile battery electrode connectionmember comprising: an inner conductive surface configured to establishelectrical communication with one battery electrode surface of athin-profile battery received by the connection member; an outerperipheral conductive surface, the inner and outer surfaces beingoriented within respective planes which are generally parallel with oneanother; and an intermediate conductive surface joined with andextending between the inner and outer surfaces, the surfacescollectively defining a container for receiving at least onethin-profile battery, the intermediate surface being dimensioned toachieve substantial elevational alignment of the outer surface and asecond battery electrode surface of a thin-profile battery received bythe connection member.
 14. The thin-profile battery electrode connectionmember of claim 13, wherein the one battery electrode surface and thesecond battery electrode surface comprise different electrode surfacesof a single thin-profile battery.
 15. The thin-profile battery electrodeconnection member of claim 13, wherein the one battery electrode surfaceand the second battery electrode surface comprise different electrodesurfaces of different thin-profile batteries.
 16. The thin-profilebattery electrode connection member of claim 13, wherein theintermediate conductive surface includes at least a portion whichextends at an angle which is oblique relative to the inner conductivesurface plane.
 17. The thin-profile battery electrode connection memberof claim 16, wherein the one battery electrode surface and the secondbattery electrode surface comprise different electrode surfaces ofdifferent thin-profile batteries.
 18. The thin-profile battery electrodeconnection member of claim 16, wherein a substantial portion of theintermediate conductive surface extends at the angle which is obliquerelative to the inner conductive surface.
 19. The thin-profile batteryelectrode connection member of claim 13, wherein: the intermediateconductive surface joins with the inner and outer conductive surfaces atrespective joinder locations; and the intermediate conductive surfacetapers between the joinder locations.
 20. The thin-profile batteryelectrode connection member of claim 19, wherein the intermediateconductive surface tapers outwardly from the joinder location at theinner conductive surface toward the joinder location at the outerconductive surface.
 21. The thin-profile battery electrode connectionmember of claim 13, wherein: the connection member has a thicknessdimension adjacent the inner conductive surface and in a direction whichis normal to a plane defined by the inner conductive surface; and theouter conductive surface comprises first and second boundary edgeshaving a minimum separation distance therebetween which is greater thanthe thickness dimension of the connection member.
 22. The thin-profilebattery electrode connection member of claim 21, wherein the first andsecond boundary edges are generally circular in shape and concentricwith one another.
 23. The thin-profile battery electrode connectionmember of claim 4, wherein the internal volume is sized to receive atleast most all of each of at least two thin-profile batteries.
 24. Thethin-profile battery electrode connection member of claim 4, wherein theinternal volume is sized to receive all of each of at least twothin-profile batteries.
 25. The thin-profile battery electrodeconnection member of claim 1, wherein the internal volume is sized toreceive all of at least one thin-profile battery.
 26. The button-typebattery electrode connection member of claim 9, wherein the internalvolume is sized to receive all of at least one button-type battery. 27.The button-type battery electrode connection member of claim 10, whereinthe internal volume is sized to receive at least most all of each of atleast two button-type batteries.
 28. The button-type battery electrodeconnection member of claim 10, wherein the internal volume is sized toreceive all of each of at least two button-type batteries.
 29. Thethin-profile battery electrode connection member of claim 21, whereinthe intermediate surface is dimensioned to achieve exact elevationalalignment of the outer surface and the second battery electrode surfaceof a thin-profile battery received by the connection member.